Method and apparatus for consolidating a bulk molding compound

ABSTRACT

Methods and an apparatus are presented. A bulk molding compound is consolidated by sending the bulk molding compound through a die breaker and an extrusion die of a consolidation system.

BACKGROUND INFORMATION 1. Field

The present disclosure relates generally to manufacturing compositestructures and, more specifically, to composite materials used inmolding processes. Yet more specifically, the present disclosurepresents methods and an apparatus for consolidating a bulk moldingcompound.

2. Background

Bulk molding compound is used to form composite structures in moldingprocesses. Bulk molding compound is a compound formed from choppedfibers and at least one resin material. The chopped fibers contributestrength to composite structures formed by the bulk molding compound.Composite structures formed from bulk molding compound may not be asstrong as desired.

Therefore, it would be desirable to have a method and apparatus thattake into account at least some of the issues discussed above, as wellas other possible issues. For example, it would be desirable to formcomposite structures having a lower porosity through molding processes.As another example, it would be desirable to form composite structureswith fewer inconsistencies through molding processes.

SUMMARY

An illustrative embodiment of the present disclosure provides a method.A bulk molding compound is consolidated by sending the bulk moldingcompound through a die breaker and an extrusion die of a consolidationsystem.

Another illustrative embodiment of the present disclosure provides amethod. A bulk molding compound is heated to form a heated bulk moldingcompound. The heated bulk molding compound is loaded into aconsolidation system. The heated bulk molding compound is pressed toform a pressed material. The pressed material is extruded through anextrusion die of the consolidation system.

Yet another illustrative embodiment of the present disclosure provides aconsolidation system. The consolidation system comprises a die breakerand an extrusion die.

A further illustrative embodiment of the present disclosure provides amethod. A bulk molding compound is heated to form a heated bulk moldingcompound. The heated bulk molding compound is degassed in aconsolidation system. The heated bulk molding compound is consolidatedafter degassing, in which consolidating comprises pressing the heatedbulk molding compound through a die breaker form a pressed material. Thepressed material is relaxed. The pressed material is extruded through anextrusion die of the consolidation system after relaxing the pressedmaterial.

The features and functions can be achieved independently in variousembodiments of the present disclosure or may be combined in yet otherembodiments in which further details can be seen with reference to thefollowing description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the illustrativeembodiments are set forth in the appended claims. The illustrativeembodiments, however, as well as a preferred mode of use, furtherobjectives and features thereof, will best be understood by reference tothe following detailed description of an illustrative embodiment of thepresent disclosure when read in conjunction with the accompanyingdrawings, wherein:

FIG. 1 is an illustration of a block diagram of a manufacturingenvironment in which a bulk molding compound is consolidated inaccordance with an illustrative embodiment;

FIG. 2 is an illustration of a manufacturing environment in which a bulkmolding compound is consolidated in accordance with an illustrativeembodiment;

FIG. 3 is an illustration of a cross-sectional view of a consolidationsystem in which a bulk molding compound is consolidated in accordancewith an illustrative embodiment;

FIG. 4 is an illustration of a cross-sectional view of a consolidationsystem in which a bulk molding compound is consolidated in accordancewith an illustrative embodiment;

FIG. 5 is an illustration of an isometric view of a die breaker of aconsolidation system in accordance with an illustrative embodiment;

FIG. 6 is an illustration of a front view of a die breaker of aconsolidation system in accordance with an illustrative embodiment;

FIG. 7 is an illustration of a flowchart of a method for consolidating abulk molding compound in accordance with an illustrative example;

FIG. 8 is an illustration of a flowchart of a method for consolidating abulk molding compound in accordance with an illustrative example;

FIG. 9 is an illustration of a flowchart of a method for consolidating abulk molding compound in accordance with an illustrative example;

FIG. 10 is an illustration of an aircraft manufacturing and servicemethod in the form of a block diagram in accordance with an illustrativeexample; and

FIG. 11 is an illustration of an aircraft in the form of a block diagramin which an illustrative example may be implemented.

DETAILED DESCRIPTION

The illustrative embodiments recognize and take into account one or moredifferent considerations. For example, the illustrative embodimentsrecognize and take into account that bulk molding compound (BMC), orbulk molding composite, is used in several industries and severaldifferent platforms such as, for example, a mobile platform, astationary platform, a land-based structure, an aquatic-based structure,or a space-based structure. More specifically, a platform may be asurface ship, a tank, a personnel carrier, a train, a spacecraft, aspace station, a satellite, a submarine, an automobile, a power plant, abridge, a dam, a house, a manufacturing facility, a building, anappliance, or some other suitable platform. The illustrative embodimentsrecognize and take into account that bulk molding compound may be usedin electrical applications, corrosion resistant applications, or otherapplications with specific technical or performance standards.

The illustrative embodiments recognize and take into account that bulkmolding compound is commercially available and may include any desirabletype or mixture of types of chopped fibers. The illustrative embodimentsrecognize and take into account that the chopped fibers may includeglass, carbon, Kevlar, or any other desirable type of fibers. Theillustrative embodiments recognize and take into account that the bulkmolding compound may include either a thermoset or a thermoplastic resinsystem. The illustrative embodiments recognize and take into accountthat the bulk molding compound may include any desirable type of polymerresin system, such as an epoxy, a phenolic, a polyester resin, a vinylester, Polyetheretherketone (PEEK)/Polyetherketoneketone (PEKK),Polyphenylsulfone (PPSU), a polyamide, or any other desirable type ofresin system.

The illustrative embodiments recognize and take into account that bulkmolding compound is commercially available and provided in a state thatis ready for molding. The illustrative embodiments recognize and takeinto account that bulk molding compound may be provided in bulk or logs.

The illustrative embodiments recognize and take into account that bulkmolding compound is manufactured by mixing strands of chopped fibers ina mixer with a resin. The illustrative embodiments recognize and takeinto account that the chopped fibers in bulk molding compound contributeto the strength properties of the composite structures formed by thebulk molding compound. The illustrative embodiments recognize and takeinto account that in some instances, the chopped fibers in the bulkmodeling compound may create greater strength than the neat resinsystem, e.g., epoxy without fiber reinforcement.

The illustrative embodiments recognize and take into account that athigh fiber volume fraction, it may be more challenging than desired tofully wet all of the chopped fibers in the bulk molding compound. Theillustrative embodiments recognize and take into account that it may bemore challenging than desired to make a fully consolidated bulk moldingcompound for final application.

The illustrative embodiments recognize and take into account that a notfully consolidated bulk molding compound may create inconsistencies inthe cured composite material. The illustrative embodiments recognize andtake into account that a not fully consolidated bulk molding compoundmay produce less than desirable quality in the cured material. Theillustrative embodiments recognize and take into account that a notfully consolidated bulk molding compound may produce higher thandesirable porosity levels in the cured material.

The illustrative examples recognize and take into account that compositematerials may be used to form composite radius fillers or composite“noodles.” The illustrative examples recognize and take into accountthat composite radius fillers desirably have axially aligned fibers toprovide tension strength.

Referring now to the figures and, in particular, with reference to FIG.1, an illustration of a block diagram of a manufacturing environment inwhich a bulk molding compound is consolidated is depicted in accordancewith an illustrative embodiment. Manufacturing environment 100 hasconsolidation system 102 configured to consolidate bulk molding compound104. Bulk molding compound 104 is loose composite material 106 formed ofresin 108 and fillers 110. In some illustrative examples, fillers 110take the form of fibers 112. Fibers 112 may be formed of any desirablematerial and have any desirable size. In some illustrative examples,fibers 112 have lengths in the range of 0.125″ to 1.0″. By consolidatingbulk molding compound 104, porosity 114 in consolidated material 116 islower than porosity 118 in bulk molding compound 104.

Consolidation system 102 comprises die breaker 120 and extrusion die122. In some illustrative examples, bulk molding compound 104 isconsolidated by sending bulk molding compound 104 through die breaker120 and extrusion die 122.

Consolidation system 102 further comprises piston 124 and cylindricalhousing 126. Die breaker 120 is contained within cylindrical housing126. Extrusion die 122 is connected to end 128 of cylindrical housing126. In some illustrative examples, consolidation system 102 is referredto as a “ram extruder.”

Relaxation chamber 130 is formed by die breaker 120, cylindrical housing126, and extrusion die 122. Bulk molding compound 104 is pressed throughdie breaker 120 to become pressed material 132 within relaxation chamber130. Relaxation chamber 130 is used to stabilize material form.

Relaxation gives the pressed material 132 time to remix and expand priorto extrusion through extrusion die 122. Relaxation reduces expansionafter extrusion through extrusion die 122. In some illustrativeexamples, relaxation reduces the porosity of consolidated material 116.

In some illustrative examples, relaxation chamber 130 may also bereferred to as an “extrusion zone.” In relaxation chamber 130, pressedmaterial 132 is remixed after die breaker 120 and relaxes before beingextruded through extrusion die 122. Remixing pressed material 132 aidsin equal wetting of fillers 110 with resin 108. By relaxing, pressedmaterial 132 does not retain the shape of plurality of holes 144 orplurality of slots 146 of die breaker 120.

When present, die breaker 120 provides for back pressure enhancement forextrusion die 122. When die breaker 120 is present, consolidatedmaterial 116 expands less after extrusion than when die breaker 120 isnot present. When die breaker 120 is present, die breaker 120 increaseshomogenization of consolidated material 116.

Die breaker 120 has any desirable size and shape. For example, diebreaker 120 has thickness 121. Thickness 121 is selected to provideconsolidation to bulk molding compound 104. Thickness 121 is selected sothat bulk molding compound 104 spends sufficient time moving through diebreaker 120 such that bulk molding compound 104 is consolidated. In someillustrative examples, thickness 121 is in the range of 0.25 inches to1.0 inch. In some illustrative examples, thickness 121 is approximately0.5 inches.

Prior to being pressed through die breaker 120, bulk molding compound104 is loaded into compression chamber 134. Compression chamber 134 isformed by die breaker 120, piston 124, and cylindrical housing 126.

In some illustrative examples, compression chamber 134 may be referredto as a “material feed chamber.” Bulk molding compound 104 incompression chamber 134 has a lower density than pressed material 132 inrelaxation chamber 130. More specifically, density 135 of bulk moldingcompound 104 is lower than density 137 of pressed material 132.

By piston 124 moving towards extrusion die 122, bulk molding compound104 is mixed and consolidated. Movement of bulk molding compound 104within compression chamber 134 mixes resin 108 and fillers 110. Bulkmolding compound 104 is consolidated through at least one of appliedforce, heating, or degassing.

In some illustrative examples, prior to loading bulk molding compound104 into consolidation system 102, heating 136 is applied to bulkmolding compound 104 to form heated bulk molding compound 138. In theseillustrative examples, heated bulk molding compound 138 is loaded intoconsolidation system 102.

In these illustrative examples, bulk molding compound 104 is heated toabove the glass transition temperature Tg of resin 108 so that bulkmolding compound 104 is significantly softened. The temperature shouldalso be well below the cure temperature of resin 108 so that no chemicalreaction is trigged due to this operation. In some illustrativeexamples, heating 136 is performed until resin 108 is flowable.

After loading heated bulk molding compound 138 into consolidation system102, heated bulk molding compound 138 is degassed. To degas heated bulkmolding compound 138, a vacuum is applied to heated bulk moldingcompound 138. The vacuum is applied through vacuum port 140 withincylindrical housing 126. The vacuum applied through vacuum port 140degasses heated bulk molding compound 138 initially within compressionchamber 134. The vacuum also evacuates gases from compression chamber134 and relaxation chamber 130.

Degassing heated bulk molding compound 138 removes gases from heatedbulk molding compound 138. Removing gases from heated bulk moldingcompound 138 increases density 135 of bulk molding compound 104 withincylindrical housing 126.

In order to degas heated bulk molding compound 138, cylindrical housing126 is sealed. Cylindrical housing 126 is sealed by associating anairtight component, such as plug 141, with end 128 of cylindricalhousing 126 and another airtight component, such as piston 124, with end168 of cylindrical housing 126.

In some illustrative examples, piston 124 seals cylindrical housing 126to enable a vacuum to be applied to pull gas out of heated bulk moldingcompound 138. In these illustrative examples, piston 124 forms anairtight seal with cylindrical housing 126. In some other illustrativeexamples, piston 124 does not form an airtight seal with cylindricalhousing 126. In these illustrative examples, a separate sealingcomponent (not depicted) is associated with end 168 to seal cylindricalhousing 126.

In some illustrative examples, a vacuum is applied through vacuum port140 prior to pressing heated bulk molding compound 138 and the vacuum isno longer applied through vacuum port 140 after piston 124 extends pastvacuum port 140. In these illustrative examples, piston 124 forms anairtight seal with cylindrical housing 126.

In some illustrative examples, a vacuum is applied throughout pressingheated bulk molding compound 138 through die breaker 120 ofconsolidation system 102. In these illustrative examples, a separatesealing component (not depicted) seals cylindrical housing 126 at end168.

Plug 141 is associated with end 128 of cylindrical housing 126. Plug 141seals end 128 of cylindrical housing 126 for application of vacuumthrough vacuum port 140. Plug 141 seals cylindrical housing 126 byblocking opening 152 of extrusion die 122. Plug 141 maintains the vacuumwithin cylindrical housing 126.

Plug 141 remains in place until pressed material 132 forces plug 141 outof opening 152. When pressed material 132 forces plug 141 out of opening152, pressed material 132 passing through opening 152 maintains thevacuum within cylindrical housing 126.

After applying vacuum through vacuum port 140, actuator 142 moves piston124 to press heated bulk molding compound 138 within cylindrical housing126 of consolidation system 102. Pressing heated bulk molding compound138 through die breaker 120 of consolidation system 102 comprisesdriving piston 124 towards extrusion die 122.

As depicted, pressing heated bulk molding compound 138 of consolidationsystem 102 to form pressed material 132 comprises pressing heated bulkmolding compound 138 through die breaker 120 of consolidation system102. Die breaker 120 includes at least one of plurality of holes 144 orplurality of slots 146.

As used herein, the phrase “at least one of,” when used with a list ofitems, means different combinations of one or more of the listed itemsmay be used, and only one of each item in the list may be needed. Inother words, “at least one of” means any combination of items and numberof items may be used from the list, but not all of the items in the listare required. The item may be a particular object, a thing, or acategory.

For example, “at least one of item A, item B, or item C” may include,without limitation, item A, item A and item B, or item B. This examplealso may include item A, item B, and item C, or item B and item C. Ofcourse, any combination of these items may be present. In otherexamples, “at least one of” may be, for example, without limitation, twoof item A, one of item B, and ten of item C; four of item B and seven ofitem C; or other suitable combinations.

As depicted, consolidation system 102 includes heater system 148associated with cylindrical housing 126. Heater system 148 includes anydesirable quantity of heaters and any desirable type of heaters. Heatersystem 148 may be one of a convection heating system or a conductionheating system. By being associated with cylindrical housing 126, heatersystem 148 is configured to heat cylindrical housing 126. In someillustrative examples, heater system 148 is associated with cylindricalhousing 126 by being directed at cylindrical housing 126. For example,heater system 148 may be a heated air source directed to blow the heatedair across cylindrical housing.

In some illustrative examples, heater system 148 is associated withcylindrical housing 126 by contacting cylindrical housing 126. Forexample, a heating blanket may be wrapped around cylindrical housing 126to heat cylindrical housing 126 to form heater system 148. In someillustrative examples, heater system 148 is associated with cylindricalhousing 126 by being built into cylindrical housing 126. For example,resistive heating elements may be built into cylindrical housing 126 toform heater system 148.

Heater system 148 applies heat 150 to cylindrical housing 126 to reduceviscosity of bulk molding compound 104 within cylindrical housing 126.By reducing the viscosity of bulk molding compound 104 withincylindrical housing 126, the force provided by actuator 142 to pressbulk molding compound 104 through die breaker 120 is reduced. Reducingthe viscosity of bulk molding compound 104 in cylindrical housing 126creates better processability. Reducing viscosity also leads to betterdegassing of bulk molding compound 104.

In some illustrative examples, extrusion die 122 may also be referred toas a forming die. Extrusion die 122 has opening 152 through whichconsolidated material 116 exits consolidation system 102. Extrusion die122 forms consolidated material 116 into one of slug 154 or ingot 156.

Ingot 156 has any desirable profile, such as round, square, rectangular,triangular, or any other desirable profile. Opening 152 is shaped tocreate the desired profile of slug 154 or ingot 156. Opening 152 has anydesirable size or shape based on a desired shape for slug 154 or ingot156. Opening 152 has cross-sectional shape 157. Cross-sectional shape157 is any desirable shape, such as round, square, rectangular,triangular, or any other desirable shape. In some illustrative examples,extrusion die 122 has opening 152 with cross-sectional shape 157configured to form a composite radius filler.

In one illustrative example, extrusion die 122 is a slotted rectangulardie. In this illustrative example, opening 152 of extrusion die 122 isused to extrude the material into thin sheets for forming into a bracketor thin shelled panel structures. In one illustrative example, extrusiondie 122 has opening 152 with a triangular shape. In this illustrativeexample, extrusion die 122 with opening 152 having a triangular shapemay be used to extrude bulk molding compound 104 for a radius fillerapplication.

Consolidated material 116 is a material to be used for forming acomposite structure, such as composite structure 158. Consolidatedmaterial 116 exiting extrusion die 122 is ready for a molding process,such as molding 160. As depicted, after exiting consolidation system102, consolidated material 116 goes through molding 160 to formcomposite structure 158. In some illustrative examples, consolidatedmaterial 116 may be stored for a desired period of time prior to molding160.

Composite structure 158 may have at least one of a lower porosity, fewerinconsistencies, or higher strength than a composite structure formedfrom bulk molding compound 104. Consolidating bulk molding compound 104to create consolidated material 116 prior to forming composite structure158 increases the quality of composite structure 158. In someillustrative examples, composite structure 158 is a part for anaircraft.

Consolidating bulk molding compound 104 using consolidation system 102is a batch process. Consolidation system 102 may have any desirabledimensions. Volume 162 of compression chamber 134 affects the amount ofbulk molding compound 104 that may be processed in a batch.

Diameter 164 of cylindrical housing 126 affects the amount of forcesupplied by actuator 142. Increasing diameter 164 increases the amountof force supplied by actuator 142 to consolidate bulk molding compound104.

Diameter 164 of cylindrical housing 126 also affects volume 162 ofcompression chamber 134. Increasing diameter 164 of cylindrical housing126 increases volume 162 of compression chamber 134. Volume 162 ofcompression chamber 134 is also affected by distance 166 between diebreaker 120 and end 168 of cylindrical housing 126. For example,increasing distance 166 between die breaker 120 and end 168 increasesvolume 162. End 128 and end 168 of cylindrical housing 126 are oppositeends of cylindrical housing 126.

Extrusion die 122 has any desirable dimensions. In some illustrativeexamples, cross-sectional area 172 of opening 152 is at least 25% lessthan cross-sectional area 174 of cylindrical housing 126. In someillustrative examples, when opening 152 is circular, diameter 170 ofopening 152 of extrusion die 122 is at least 25% less than diameter 164of cylindrical housing 126.

The illustration of manufacturing environment 100 in FIG. 1 is not meantto imply physical or architectural limitations to the manner in which anillustrative embodiment may be implemented. Other components in additionto or in place of the ones illustrated may be used. Some components maybe unnecessary. Also, the blocks are presented to illustrate somefunctional components. One or more of these blocks may be combined,divided, or combined and divided into different blocks when implementedin an illustrative embodiment.

For example, either bulk molding compound 104 or heated bulk moldingcompound 138 may be loaded into consolidation system 102 andconsolidated using consolidation system 102. As another example,although die breaker 120 is present, in some illustrative examples, diebreaker 120 may not be present in consolidation system 102.

As another example, although extrusion die 122 is shown as having onlyopening 152, extrusion die may have any desirable quantity of openings.In some illustrative examples, extrusion die 122 has more than oneopening.

In some illustrative examples, consolidation system 102 is moved withinmanufacturing environment 100 by an automated movement system, such as arobotic arm. In these illustrative examples, consolidation system 102may be a part of an end effector. In some illustrative examples, toolingis moved relative to consolidation system 102 to receive consolidatedmaterial 116.

As a further example, although molding 160 is shown, molding 160 may beoptional. In some illustrative examples, consolidated material 116 formscomposite structure 158 without molding 160. For example,cross-sectional shape 157 of opening 152 may form consolidated material116 into slug 154 having a desired cross-sectional shape for a compositeradius filler.

In some these illustrative examples, consolidation system 102 may bepart of a composite radius filler end effector. In one illustrativeexample, consolidation system 102 is an end effector (not depicted)configured to extrude a composite radius filler to form compositestructure 158. In some illustrative examples, consolidation system 102extrudes consolidated material 116 directly onto another compositematerial to form a composite radius filler. In some illustrativeexamples, consolidation system 102 extrudes consolidated material 116onto a tool to form a composite radius filler.

Turning now to FIG. 2, an illustration of a manufacturing environment inwhich a bulk molding compound is consolidated is depicted in accordancewith an illustrative embodiment. Manufacturing environment 200 is aphysical implementation of manufacturing environment 100 of FIG. 1.Manufacturing environment 200 includes consolidation system 202 and bulkmolding compound 204. Bulk molding compound 204 is a physicalimplementation of bulk molding compound 104 of FIG. 1.

As depicted, consolidated material 206 is extruded from consolidationsystem 202. Consolidated material 206 has a porosity (not depicted) thatis less than a porosity (not depicted) of bulk molding compound 204.

To form consolidated material 206, bulk molding compound 204 is loadedinto consolidation system 202. In some illustrative examples, bulkmolding compound 204 is heated prior to loading bulk molding compound204 into cylindrical housing 208.

After loading bulk molding compound 204 into cylindrical housing 208,piston 210 is associated with cylindrical housing 208 to sealcylindrical housing 208. After sealing cylindrical housing 208 usingpiston 210, bulk molding compound 204 within cylindrical housing 208 isdegassed. To degas the material within cylindrical housing 208, a vacuumis applied within cylindrical housing 208. The vacuum is applied througha vacuum port (not depicted) in the cylindrical housing 208. The vacuumis applied to the vacuum port (not depicted) in the cylindrical housing208 by a vacuum source.

To form consolidated material 206, actuator 212 drives piston 210towards extruder die 214. Extruder die 214 is connected to end 216 ofcylindrical housing 208. By driving piston 210 towards extruder die 214,material, such as bulk molding compound 204, is pressed withincylindrical housing 208 and extruded through extruder die 214. Asdepicted, consolidated material 206 exits extruder die 214 as slug 218.

In some illustrative examples, slug 218 is subjected to an additionalmolding process to form a composite structure. In some otherillustrative examples, slug 218 is used with the extruded cross-section.For example, slug 218 may be laid down as a composite radius filler insome illustrative examples.

In some illustrative examples, consolidation system 202 is part of anend effector to apply slug 218 to a composite material or tooling. Insome illustrative examples, consolidation system 202 is part of acomposite radius filler extruding end effector in which slug 218 is usedas a composite radius filler.

Turning now to FIG. 3, an illustration of a cross-sectional view of aconsolidation system in which a bulk molding compound is consolidated isdepicted in accordance with an illustrative embodiment. Consolidationsystem 300 is a physical implementation of consolidation system 102 ofFIG. 1. As depicted, consolidation system 300 has die breaker 302 andextrusion die 304. Consolidation system 300 also has piston 306 andcylindrical housing 308. Die breaker 302 is contained within cylindricalhousing 308. Extrusion die 304 is connected to end 310 of cylindricalhousing 308.

Compression chamber 312 is formed by die breaker 302, piston 306, andcylindrical housing 308. Relaxation chamber 314 is formed by die breaker302, cylindrical housing 308, and extrusion die 304.

Vacuum port 316 is within cylindrical housing 308. Heater system 318 isassociated with cylindrical housing 308. As depicted, heater system 318is incorporated into cylindrical housing 308.

As depicted, piston 306 seals cylindrical housing 308. Piston 306contacts and has an airtight seal with cylindrical housing 308. Bulkmolding compound 320 within compression chamber 312 is degassed usingvacuum port 316. Plug 321 seals cylindrical housing 308 for thedegassing. Plug 321 blocks an opening (not depicted) of extrusion die304.

As depicted, extrusion die 304 has taper 323. Due to taper 323, anopening (not depicted) of extrusion die 304 has a smaller cross-sectionthan a cross-section of cylindrical housing 308. The smallercross-section of the opening (not depicted) of extrusion die 304 helpssustain a higher pressure during extrusion. The smaller cross-section ofthe opening (not depicted) of extrusion die 304 helps to maintain a lowporosity in the extruded ingot (not depicted).

In view 322, piston 306 is at initial location 324. From initiallocation 324, piston 306 is driven by actuator 326 in direction 328towards extrusion die 304. As piston 306 moves in direction 328, piston306 will compress bulk molding compound 320 as shown in FIG. 4.

When piston 306 passes vacuum port 316, the vacuum may be released fromvacuum port 316. When piston 306 passes vacuum port 316, the airtightseal between piston 306 and cylindrical housing 308 maintains the vacuumwithin bulk molding compound 320.

In some illustrative examples, bulk molding compound 320 has beenpreheated before being placed into cylindrical housing 308. In theseillustrative examples, bulk molding compound 320 may be referred to as“heated bulk molding compound.”

Turning now to FIG. 4, an illustration of a cross-sectional view of aconsolidation system in which a bulk molding compound is consolidated isdepicted in accordance with an illustrative embodiment. In view 400,piston 306 moves in direction 328, pressing bulk molding compound 320through die breaker 302. Bulk molding compound 320 is pressed throughdie breaker 302 to form pressed material 402.

As bulk molding compound 320 is pressed through die breaker 302, greaterpressure is applied to bulk molding compound 320 due to the size ofplurality of holes 403 of die breaker 302. The greater pressure appliedto bulk molding compound 320 consolidates bulk molding compound 320.

As bulk molding compound 320 is pressed through die breaker 302, atleast a portion of the fibers within bulk molding compound 320 areaxially aligned. Aligning the fibers within the bulk molding compound320 may be desirable for some composite structures to be created fromconsolidated material 404. As depicted, bulk molding compound 320 ispressed through plurality of holes 403 of die breaker 302 to formpressed material 402.

Pressed material 402 within relaxation chamber 314 has been pressedthrough die breaker 302. Pressed material 402 is remixed and relaxedwithin relaxation chamber 314.

Relaxation chamber 314 is used to stabilize material form. Relaxationgives the pressed material 402 time to remix and expand prior toextrusion through extrusion die 304. Relaxation reduces expansion afterextrusion through extrusion die 304. In some illustrative examples,relaxation reduces the porosity of consolidated material 404.

In some illustrative examples, relaxation chamber 314 may also bereferred to as an “extrusion zone.” In relaxation chamber 314, pressedmaterial 402 is remixed after die breaker 302 and relaxes before beingextruded through extrusion die 304. Remixing pressed material 402 aidsin equal wetting of the fillers of pressed material 402 with the resinin pressed material 402. By relaxing, pressed material 402 does notretain the shape of plurality of holes 403 or a plurality of slots ofdie breaker 302.

Die breaker 302 provides for back pressure enhancement for extrusion die304. When die breaker 302 is present, consolidated material 404 expandsless after extrusion than when die breaker 302 is not present. When diebreaker 302 is present, die breaker 302 increases homogenization ofconsolidated material 404.

As piston 306 moves in direction 328, pressed material 402 is extrudedthrough extrusion die 304 of consolidation system 300. Consolidatedmaterial 404 is extruded from extrusion die 304. Consolidated material404 takes the form of slug 406. Slug 406 has a lower porosity (notdepicted) than a porosity (not depicted) of bulk molding compound 320loaded into cylindrical housing 308 in FIG. 3. Slug 406 has a lowerporosity than bulk molding compound 320 due to the heating, degassing,and compression applied by consolidation system 300. Slug 406 has alower porosity than bulk molding compound 320 due to the consolidationthrough die breaker 302. Slug 406 also has better wetting of fillerswithin slug 406 by the resin in slug 406 than bulk molding compound 320due to the compression applied by consolidation system 300.

After exiting consolidation system 300, consolidated material 404 isready to be formed in a separate manufacturing process. In someillustrative examples, consolidated material 404 is used in a moldingapplication. Forming a component (not depicted) by molding consolidatedmaterial 404 creates a component with a higher quality than a componentformed by molding bulk molding compound 320 directly. The reducedporosity of molding consolidated material 404 results in a componentwith a higher quality than a component formed by molding bulk moldingcompound 320 directly.

In some illustrative examples, consolidated material 404 in slug 406 isnot subjected to an additional molding process to form a compositestructure. In some illustrative examples, slug 406 is used with theextruded cross-section. For example, slug 406 may be laid down as acomposite radius filler in some illustrative examples.

In some illustrative examples, consolidation system 300 is part of anend effector to apply slug 406 to a composite material or tooling. Insome illustrative examples, consolidation system 300 is part of acomposite radius filler extruding end effector in which slug 406 is usedas a composite radius filler.

Slug 406 may have any desirable shape. In some illustrative examples, ashape of slug 406 is selected based on a composite structure to beformed. In some illustrative examples, slug 406 may instead be one ormore thin sheets. The thin sheets may be formed into a bracket, a panel,or any other desirable composite structure.

Turning now to FIG. 5, an illustration of an isometric view of a diebreaker of a consolidation system is depicted in accordance with anillustrative embodiment. Die breaker 500 is a physical implementation ofdie breaker 120 of FIG. 1. Die breaker 500 may be used in consolidationsystem 102 of FIG. 1. Die breaker 500 may be the same as die breaker 302of FIGS. 3 and 4.

Die breaker 500 comprises at least one of a plurality of holes or aplurality of slots. As depicted, die breaker 500 has plurality of holes502. In other non-depicted illustrative examples, die breaker 500 hasone or more slots in addition to a plurality of holes. In othernon-depicted illustrative examples, die breaker 500 has a plurality ofslots without plurality of holes 502.

As a bulk molding compound is pressed through die breaker 500, greaterpressure is applied to the bulk molding compound due to the size ofplurality of holes 502 of die breaker 500. As depicted, the diameter ofeach of plurality of holes 502 is 0.25″. As depicted, a thickness of diebreaker 500 is about 0.5″. The thickness of die breaker 500 is selectedto have a bulk molding compound pass through die breaker 500 for asufficient period of time to consolidate the bulk molding compound. Thegreater pressure applied to the bulk molding compound consolidates thebulk molding compound.

As a bulk molding compound is pressed through die breaker 500, at leasta portion of the fibers within the bulk molding compound are axiallyaligned. Aligning the fibers within the bulk molding compound may bedesirable for some composite structures to be created from aconsolidated material formed using a consolidation system comprising diebreaker 500.

Turning now to FIG. 6, an illustration of a front view of a die breakerof a consolidation system is depicted in accordance with an illustrativeembodiment. Die breaker 600 is a physical implementation of die breaker120 of FIG. 1. Die breaker 600 may be used in consolidation system 102of FIG. 1. Die breaker 600 may be the same as die breaker 302 of FIGS. 3and 4.

Die breaker 600 comprises at least one of a plurality of holes or aplurality of slots. As depicted, die breaker 600 has plurality of slots602. In other non-depicted illustrative examples, die breaker 600 hasone or more holes in addition to plurality of slots 602. In othernon-depicted illustrative examples, die breaker 600 has a plurality ofholes without plurality of slots 602.

As a bulk molding compound is pressed through die breaker 600, greaterpressure is applied to the bulk molding compound due to the size ofplurality of slots 602 of die breaker 600. As depicted, the length ofplurality of slots 602 is not identical. In some illustrative examples,the length of each of plurality of slots 602 is in the range of 0.25″ to0.5″. The greater pressure applied to the bulk molding compoundconsolidates the bulk molding compound.

As a bulk molding compound is pressed through die breaker 600, at leasta portion of the fibers within the bulk molding compound are axiallyaligned. Aligning the fibers within the bulk molding compound may bedesirable for some composite structures to be created from aconsolidated material formed using a consolidation system comprising diebreaker 600.

The different. components shown in FIGS. 2-6 may be combined withcomponents in FIG. 1, used with components in FIG. 1, or a combinationof the two. Additionally, some of the components in FIGS. 2-6 may beillustrative examples of how components shown in block form in FIG. 1may be implemented as physical structures.

Turning now to FIG. 7, an illustration of a flowchart of a method forconsolidating a bulk molding compound is depicted in accordance with anillustrative embodiment. Method 700 may be used to consolidate bulkmolding compound 104 using consolidation system 102 of FIG. 1. Method700 may be implemented in manufacturing environment 200 usingconsolidation system 202 of FIG. 2. Method 700 may be performed usingconsolidation system 300 of FIGS. 3 and 4. Die breaker 500 of FIG. 5 maybe used to perform method 700.

Method 700 consolidates a bulk molding compound by sending the bulkmolding compound through a die breaker and an extrusion die of aconsolidation system (operation 702). Afterwards, method 700 terminates.

In some illustrative examples, method 700 heats the bulk moldingcompound prior to loading the bulk molding compound into theconsolidation system (operation 704). By pre-heating the bulk moldingcompound prior to loading into the consolidation system, the initiationof pressure by the piston may be started earlier than by heating thebulk molding compound entirely by a heating system associated with thecylindrical housing.

In some illustrative examples, method 700 degasses the bulk moldingcompound within the cylindrical housing (operation 706). Degassing thebulk molding compound removes gases from the bulk molding compound toincrease the density of the consolidated material. In some illustrativeexamples, method 700 degasses the bulk molding compound by applying avacuum to the bulk molding compound. In some illustrative examples, thevacuum is applied until the piston passes by the vacuum port.

In some illustrative examples, consolidating the bulk molding compoundcomprises sending the bulk molding compound through the die breakerwithin the consolidation system (operation 708); and extruding the bulkmolding compound through the extrusion die of the consolidation systemafter sending the bulk molding compound through the die breaker(operation 710). In some illustrative examples, sending the bulk moldingcompound through the die breaker comprises compressing the bulk moldingcompound within a cylindrical housing of the consolidation system usinga piston (operation 712). The piston may also be referred to as a“compression piston.” The piston may be driven by an actuator or anyother desirable driving mechanism.

In some illustrative examples, sending the bulk molding compound throughthe die breaker within the consolidation system comprises sending thebulk molding compound through at least one of a plurality of holes or aplurality of slots (operation 714). The at least one of the plurality ofholes or the plurality of slots may have any desirable layout, anydesirable size, and any desirable quantity. In some illustrativeexamples, sending the bulk molding compound through at least one of aplurality of holes or a plurality of slots consolidates the bulk moldingcompound (operation 716).

In some illustrative examples, sending the bulk molding compound throughthe die breaker axially aligns at least a portion of fibers in the bulkmolding compound (operation 718). As the bulk molding compound ispressed through the die breaker, greater pressure is applied to the bulkmolding compound due to the size of a plurality of holes or a pluralityof slots of die breaker. The greater pressure applied to the bulkmolding compound consolidates bulk molding compound. In someillustrative examples, method 700 relaxes the bulk molding compoundbetween sending the bulk molding compound through the die breaker andextruding the bulk molding compound (operation 720).

In some illustrative examples, method 700 heats the cylindrical housingof the consolidation system (operation 722). By heating the cylindricalhousing, the bulk molding compound within the cylindrical housing isheated. Heating the bulk molding compound reduces the viscosity of thebulk molding compound.

The cylindrical housing is heated using any desirable heating process.The heater system may be associated with the cylindrical housing bybeing directed at, contacting, being connected to, or being formedwithin the cylindrical housing.

Turning now to FIG. 8, an illustration of a flowchart of a method forconsolidating a bulk molding compound is depicted in accordance with anillustrative example. Method 800 may be used to consolidate bulk moldingcompound 104 using consolidation system 102 of FIG. 1. Method 800 may beimplemented in manufacturing environment 200 using consolidation system202 of FIG. 2. Method 800 may be performed using consolidation system300 of FIGS. 3 and 4. Die breaker 500 of FIG. 5 may be used to performmethod 800.

Method 800 heats a bulk molding compound to form a heated bulk moldingcompound (operation 802). Method 800 loads the heated bulk moldingcompound into a consolidation system (operation 804). Method 800 pressesthe heated bulk molding compound to form a pressed material (operation806). Method 800 extrudes the pressed material through an extrusion dieof the consolidation system (operation 808). Afterwards, method 800terminates.

In some illustrative examples, method 800 heats a cylindrical housing ofthe consolidation system (operation 810). The cylindrical housing may beheated in any desirable fashion and by any desirable heater system. Theheater system may be associated with the cylindrical housing by beingdirected at, contacting, being connected to, or being formed within thecylindrical housing.

In some illustrative examples, method 800 degasses the heated bulkmolding compound after loading the heated bulk molding compound into theconsolidation system (operation 812). The heated bulk molding compoundis degassed by applying a vacuum to the heated bulk molding compoundwithin the consolidation system. Prior to degassing the heated bulkmolding compound, the consolidation system is sealed.

In some illustrative examples, pressing the heated bulk molding compoundof the consolidation system to form the pressed material comprisespressing the heated bulk molding compound through a die breaker of theconsolidation system (operation 814). In some illustrative examples,pressing the heated bulk molding compound through the die breaker of theconsolidation system comprises driving a piston towards the extrusiondie (operation 816).

In some illustrative examples, pressing the heated bulk molding compoundthrough the die breaker of the consolidation system comprises sendingthe heated bulk molding compound through at least one of a pluralityholes or a plurality of slots (operation 818). The at least one of theplurality of holes or the plurality of slots of the die breaker may haveany desirable layout, any desirable size, and any desirable quantity.

As the heated bulk molding compound is pressed through the die breaker,at least a portion of the fibers within the heated bulk molding compoundare axially aligned. For some composite structures, axially alignedfibers desirably strengthen the composite structure. Having axiallyaligned fibers will make a composite structure stronger in tension. Insome illustrative examples, the consolidated material extruded from theconsolidation system forms a composite radius filler. Having axiallyaligned fibers will desirably make a composite radius filler stronger intension.

As the heated bulk molding compound is pressed through the die breaker,greater pressure is applied to the heated bulk molding compound due tothe size of a plurality of holes or a plurality of slots of die breaker.The greater pressure applied to the heated bulk molding compoundconsolidates bulk molding compound.

Turning now to FIG. 9, an illustration of a flowchart of a method forconsolidating a bulk molding compound is depicted in accordance with anillustrative example. Method 900 may be used to consolidate bulk moldingcompound 104 using consolidation system 102 of FIG. 1. Method 900 may beimplemented in manufacturing environment 200 using consolidation system202 of FIG. 2. Method 900 may be performed using consolidation system300 of FIGS. 3 and 4. Die breaker 500 of FIG. 5 may be used to performmethod 900.

Method 900 heats a bulk molding compound to form a heated bulk moldingcompound (operation 902). Method 900 degasses the heated bulk moldingcompound in a consolidation system (operation 904). Method 900consolidates the heated bulk molding compound after degassing, in whichconsolidating comprises pressing the heated bulk molding compoundthrough a die breaker form a pressed material (operation 906). Method900 relaxes the pressed material (operation 908). Method 900 extrudesthe pressed material through an extrusion die of the consolidationsystem after relaxing the pressed material (operation 910). Afterwards,method 900 terminates.

In some illustrative examples, pressing the heated bulk molding compoundthrough the die breaker axially aligns at least a portion of fibers inthe heated bulk molding compound (operation 912). In some illustrativeexamples, extruding the pressed material axially aligns at least aportion of fibers in the pressed material (operation 914). In someillustrative examples, extruding the pressed material forms a compositeradius filler.

The flowcharts and block diagrams in the different depicted embodimentsillustrate the architecture, functionality, and operation of somepossible implementations of apparatus and methods in an illustrativeembodiment. In this regard, each block in the flowcharts or blockdiagrams may represent a module, a segment, a function, and/or a portionof an operation or step.

In some alternative implementations of an illustrative embodiment, thefunction or functions noted in the blocks may occur out of the ordernoted in the figures. For example, in some cases, two blocks shown insuccession may be executed substantially concurrently, or the blocks maysometimes be performed in the reverse order, depending upon thefunctionality involved. Also, other blocks may be added, in addition tothe illustrated blocks, in a flowchart or block diagram.

In some illustrative examples, not all blocks of method 700, method 800,or method 900 are performed. For example, some of operations 704 through716 may be optional. In some illustrative examples, some of operations810 through 818 may be optional. In some illustrative examples,operations 912 through 914 may be optional.

The illustrative examples of the present disclosure may be described inthe context of aircraft manufacturing and service method 1000 as shownin FIG. 10 and aircraft 1100 as shown in FIG. 11. Turning first to FIG.10, an illustration of an aircraft manufacturing and service method isdepicted in accordance with an illustrative example. Duringpre-production, aircraft manufacturing and service method 1000 mayinclude specification and design 1002 of aircraft 1100 in FIG. 11 andmaterial procurement 1004.

During production, component and subassembly manufacturing 1006 andsystem integration 1008 of aircraft 1100 takes place. Thereafter,aircraft 1100 may go through certification and delivery 1010 in order tobe placed in service 1012. While in service 1012 by a customer, aircraft1100 is scheduled for maintenance and service 1014, which may includemodification, reconfiguration, refurbishment, and other maintenance orservice.

Each of the processes of aircraft manufacturing and service method 1000may be performed or carried out by a system integrator, a third party,and/or an operator. In these examples, the operator may be a customer.For the purposes of this description, a system integrator may include,without limitation, any number of aircraft manufacturers or major-systemsubcontractors; a third party may include, without limitation, anynumber of vendors, subcontractors, or suppliers; and an operator may bean airline, a leasing company, a military entity, a serviceorganization, and so on.

With reference now to FIG. 11, an illustration of an aircraft isdepicted in which an illustrative example may be implemented. In thisexample, aircraft 1100 is produced by aircraft manufacturing and servicemethod 1000 in FIG. 10 and may include airframe 1102 with a plurality ofsystems 1104 and interior 1106. Examples of systems 1104 include one ormore of propulsion system 1108, electrical system 1110, hydraulic system1112, and environmental system 1114. Any number of other systems may beincluded. Although an aerospace example is shown, different illustrativeexamples may be applied to other industries, such as the automotiveindustry.

Apparatuses and methods embodied herein may be employed during at leastone of the stages of aircraft manufacturing and service method 1000. Oneor more illustrative examples may be used during component andsubassembly manufacturing 1006, system integration 1008, or maintenanceand service 1014 of FIG. 10. For example, consolidated material 116 ofFIG. 1 consolidated by consolidation system 102 of FIG. 1 may be used toform a component of aircraft 1100 during component and subassemblymanufacturing 1006. As another example, consolidated material 116consolidated by consolidation system 102 may be used to form areplacement part during maintenance and service 1014 of FIG. 10.

Apparatuses and methods embodied herein may be employed in manufacturingat least one component of aircraft 1100. For example, consolidationsystem 102 of FIG. 1 creates consolidated material 116 of FIG. 1 thatmay be molded into a component for one of airframe 1102 or interior1106.

The illustrative examples provide methods and an apparatus forconsolidating a bulk molding compound. The consolidated material formedby consolidating a bulk molding compound can be used to make highquality composite products. Molding a consolidated material produces atleast one of reduced porosity or reduced inconsistencies in the moldedcomposite parts. Molding a consolidated material produces a higherquality composite part than molding a bulk molding compound. Molding aconsolidated material of the illustrative examples produces a compositepart with better structural performance.

Handling a consolidated material of the illustrative examples is easierthan handling a bulk molding compound. The bulk molding compound is aloose material and may generate undesirable amounts of fine dust. Theconsolidated material has a lower porosity and is in the form of a slugor ingot. Handling a consolidated material of the illustrative examplesproduces less fine dust than handling a bulk molding compound.

At least a portion of the fibers in the bulk molding compound areaxially aligned during the consolidation process. In some illustrativeexamples, axially aligned fibers desirably strengthen the compositestructure. For example, having axially aligned fibers will make acomposite structure stronger in tension. In some illustrative examples,the consolidated material extruded from the consolidation system forms acomposite radius filler. Having axially aligned fibers will desirablymake a composite radius filler stronger in tension.

The description of the different illustrative embodiments has beenpresented for purposes of illustration and description, and is notintended to be exhaustive or limited to the embodiments in the formdisclosed. Many modifications and variations will be apparent to thoseof ordinary skill in the art. Further, different illustrativeembodiments may provide different features as compared to otherillustrative embodiments. The embodiment or embodiments selected arechosen and described in order to best explain the principles of theembodiments, the practical application, and to enable others of ordinaryskill in the art to understand the disclosure for various embodimentswith various modifications as are suited to the particular usecontemplated.

What is claimed is:
 1. A method comprising: consolidating a bulk moldingcompound by sending the bulk molding compound through a die breaker andan extrusion die of a consolidation system.
 2. The method of claim 1,wherein consolidating the bulk molding compound comprises: sending thebulk molding compound through the die breaker within the consolidationsystem; and extruding the bulk molding compound through the extrusiondie of the consolidation system after sending the bulk molding compoundthrough the die breaker.
 3. The method of claim 2, wherein sending thebulk molding compound through the die breaker axially aligns at least aportion of fibers in the bulk molding compound.
 4. The method of claim 2further comprising: relaxing the bulk molding compound between sendingthe bulk molding compound through the die breaker and extruding the bulkmolding compound.
 5. The method of claim 2, wherein sending the bulkmolding compound through the die breaker comprises compressing the bulkmolding compound within a cylindrical housing of the consolidationsystem using a piston.
 6. The method of claim 5 further comprising:degassing the bulk molding compound within the cylindrical housing. 7.The method of claim 5 further comprising: heating the cylindricalhousing of the consolidation system.
 8. The method of claim 2, whereinsending the bulk molding compound through the die breaker within theconsolidation system comprises sending the bulk molding compound throughat least one of a plurality of holes or a plurality of slots.
 9. Themethod of claim 8, wherein sending the bulk molding compound through atleast one of a plurality of holes or a plurality of slots consolidatesthe bulk molding compound.
 10. The method of claim 1 further comprising:heating the bulk molding compound prior to loading the bulk moldingcompound into the consolidation system.
 11. The method of claim 1,wherein the bulk molding compound is a loose composite material formedof a resin and fillers.
 12. The method of claim 1, wherein consolidatingthe bulk molding compound forms a consolidated material, the methodfurther comprising: forming a composite structure from the consolidatedmaterial, wherein the composite structure is a component of an aircraft.13. The method of claim 12, wherein the composite structure is acomposite radius filler.
 14. A method comprising: heating a bulk moldingcompound to form a heated bulk molding compound; loading the heated bulkmolding compound into a consolidation system; pressing the heated bulkmolding compound to form a pressed material; and extruding the pressedmaterial through an extrusion die of the consolidation system.
 15. Themethod of claim 14 further comprising: heating a cylindrical housing ofthe consolidation system.
 16. The method of claim 14 further comprising:degassing the heated bulk molding compound after loading the heated bulkmolding compound into the consolidation system.
 17. The method of claim14, wherein pressing the heated bulk molding compound of theconsolidation system to form the pressed material comprises pressing theheated bulk molding compound through a die breaker of the consolidationsystem, and wherein pressing the heated bulk molding compound throughthe die breaker of the consolidation system comprises driving a pistontowards the extrusion die.
 18. The method of claim 17, wherein pressingthe heated bulk molding compound through the die breaker of theconsolidation system comprises sending the heated bulk molding compoundthrough at least one of a plurality holes or a plurality of slots. 19.The method of claim 14, wherein the bulk molding compound is a loosecomposite material formed of a resin and fillers.
 20. The method ofclaim 14, wherein extruding the pressed material through the extrusiondie of the consolidation system forms a consolidated material, themethod further comprising: forming a composite structure from theconsolidated material, wherein the composite structure is a component ofan aircraft.
 21. A method comprising: heating a bulk molding compound toform a heated bulk molding compound; degassing the heated bulk moldingcompound in a consolidation system; consolidating the heated bulkmolding compound after degassing, in which consolidating comprisespressing the heated bulk molding compound through a die breaker form apressed material; relaxing the pressed material; and extruding thepressed material through an extrusion die of the consolidation systemafter relaxing the pressed material.
 22. The method of claim 21, whereinpressing the heated bulk molding compound through the die breakeraxially aligns at least a portion of fibers in the heated bulk moldingcompound.
 23. The method of claim 21, wherein extruding the pressedmaterial axially aligns at least a portion of fibers in the pressedmaterial.
 24. The method of claim 21, wherein extruding the pressedmaterial forms a composite radius filler.
 25. A consolidation systemconfigured to consolidate a bulk molding compound, the consolidationsystem comprising: a die breaker; and an extrusion die.
 26. Theconsolidation system of claim 25 further comprising: a piston; and acylindrical housing, wherein the die breaker is contained within thecylindrical housing, and wherein the extrusion die is connected to anend of the cylindrical housing.
 27. The consolidation system of claim 26further comprising: a relaxation chamber formed by the die breaker, thecylindrical housing, and the extrusion die.
 28. The consolidation systemof claim 26 further comprising: a compression chamber formed by the diebreaker, the piston, and the cylindrical housing.
 29. The consolidationsystem of claim 26 further comprising: a vacuum port within thecylindrical housing.
 30. The consolidation system of claim 26 furthercomprising: a heater system associated with the cylindrical housing. 31.The consolidation system of claim 26, wherein a diameter of an openingof the extrusion die is at least 25% less than the diameter of thecylindrical housing.
 32. The consolidation system of claim 25, whereinthe die breaker comprises at least one of a plurality of holes or aplurality of slots.
 33. The consolidation system of claim 25, whereinthe extrusion die has an opening with a cross-sectional shape that isone of round, square, rectangular, or triangular.
 34. The consolidationsystem of claim 25, wherein the extrusion die has an opening with across-sectional shape configured to form a composite radius filler. 35.The consolidation system of claim 25, wherein the consolidation systemis part of an end effector.